Terminal lead insulator assembly for wound field synchronous machine

ABSTRACT

A terminal lead insulator assembly for use in a wound field synchronous machine has a generally cylindrical skirt extending in a first direction from a radially larger face. The radially larger face is formed with a plurality of radially outwardly extending ears. The ears include central openings for receiving electrical connections. A rotor assembly, a wound field synchronous machine and a method of assembling such a rotor assembly, each of which include the terminal lead insulator assembly as mentioned above, are also disclosed and claimed.

BACKGROUND

This application relates to a terminal lead insulator assembly, which properly positions and protects terminal leads for a wound field synchronous machine.

Wound field synchronous machines are known and include a main field winding which is driven to rotate relative to a main stator. The main field winding is part of a rotor assembly that also carries exciter windings. A diode pack is typically provided to rectify AC power generated by the exciter. The rectified power takes the form of DC power and is delivered to the main field windings.

In the prior art, electrical connections must be made between the main windings and the diode pack, and between the exciter windings and the diode pack.

In some prior wound field synchronous machines, the electrical connections and wires extended through a shaft which rotates with the rotor and windings. More recently, in some wound field synchronous machines, these electrical connections have been positioned outside the shaft, and are generally unprotected within the overall rotor assembly.

SUMMARY

An electrical connection protector or terminal lead insulator assembly for use in a wound field synchronous machine has a generally cylindrical skirt extending in a first direction from a radially larger face. The radially larger face is formed with a plurality of radially outwardly extending ears. The ears include central openings for receiving electrical connections. A rotor assembly, a wound field synchronous machine and a method of assembling such a rotor assembly, each of which include the terminal lead insulator assembly as mentioned above, are also disclosed and claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically shows a wound field synchronous machine.

FIG. 2A is a side view of a portion of the rotor of the wound field synchronous machine.

FIG. 2B is a perspective end view of the rotor portion show in FIG. 2A.

FIG. 3 shows a terminal lead insulator assembly.

FIG. 4 shows a first detail of the assembled rotor.

FIG. 5 shows another detail portion.

FIG. 6 shows yet another detail portion.

FIG. 7 shows geometric relationships with regard to the terminal lead insulator assembly.

FIG. 8 shows other geometric relationships.

DETAILED DESCRIPTION

FIG. 1 illustrates a wound field synchronous machine 20 schematically. A source of drive 22, such as a gas turbine engine and gear train drives a rotor assembly 24 of the wound field synchronous machine 20. Exciter rotor 28 and main rotor 26, are driven to rotate with a shaft 15, and rotate adjacent exciter stator 30, and main stator 29. The exciter rotor 28 contains the exciter rotor windings. The main rotor 26 contains the main field windings. This structure may generally be as known, and operates to generate electricity which is transmitted from the main stator 29 to a user 130. Additionally, this structure may operate to generate torque when a user 130 provides electricity to the main stator 29. The exciter rotor winding 28 operates to convert power from the exciter stator to be sent to the main field winding 26 via the diode pack 101, again as known.

FIG. 2A shows the rotor assembly 24 having the exciter rotor winding 28 removed. In addition, a diode pack, which could not be seen in FIG. 1, is also removed. As can be appreciated from FIGS. 2A, 2B and 3, there are a plurality of ears 38 associated with a terminal lead insulator assembly 32 (also referred to as electrical connection protector 32). The ears 38 mechanically support and protect connections 40 and 42, as well as receive a positioning pin 39. Positioning pin 39 serves to index and position the terminal lead assembly protector 32, and hence the connections 40 and 42. To do so, an end 141 of the positioning pin 39 is received in the diode pack 101. This properly axially positions the terminal lead assembly protector 32.

DC Connections 42 extend from the diode pack to bus bars 42, and in turn to the main rotor winding 26. There are two such connections.

AC connections 40 connect the diode assembly back to the exciter rotor. There are three such connections.

The bus bars 40 and 42 as illustrated in FIGS. 2A and 2B are shown with insulators 40, wires, etc. As can be appreciated from FIG. 2B, a skirt 34 that is generally cylindrical in shape extends toward the main rotor winding 26 from a forward face 41 of the protector 32. This skirt provides dielectric protection between the DC connections 42 and the rotor shaft 15.

As shown in FIG. 3, the terminal lead insulator assembly 32 includes the forward face 41, and the skirt 34. A plurality of ears 38A, 38B, 38C, 38D, 38E and 38F are formed in the face 41. In addition, a groove 56 is formed at an outer periphery of the skirt 34, and serves to provide clearance room for one of the bus bars 42.

As shown in FIG. 4, the exciter rotor 28 surrounds the diode pack 101 (shown schematically). A nut 122 may be placed on the end 141 to secure the positioning pin assembly 39. As can be appreciated from FIG. 4, the face 41 is also positioned radially inwardly of the exciter rotor 28.

FIG. 5 shows a detail of one of the connections 40 extending through one of the ears 38. Similarly, FIG. 6 shows one of the connections 42 for a bus bar, extending also through one of the ears 38.

In assembling the wound field synchronous machine 20, the positioning pin assembly 39 is positioned to have the end 141 extend through the diode pack 101, which has previously been positioned within the exciter rotor. The diode pack 101 is now in a fixed radial position, and thus the positioning pin is at a fixed radial position. When the positioning pin is moved into the ear 38 in the protector 32, the protector 32 will be in a fixed circumferential location. The other electrical connections can now be made through the other ears 38 such that they are all properly positioned.

FIG. 7 geometrically shows relationships on the face 41. As shown, radius R₀ extends to the inner periphery of the face 41. R₀ will also be the inner periphery of the skirt 34. A radius R₁ extends to one of the circumferential extending portions between the ears 38A and 38B. Another radius R₂ is formed between the ears 38A and 38F. R₂ is less than R₁, and also less than R₃ between ear 38F and 38E, and R₄ between ears 38C and 38D. A radius R₅ extends to each of the center points of cylindrical connection holes extending through the ears 38A, 38B, 38C, 38D and 38E. A radius R₆ extends to the outer periphery of the skirt 34 shown in phantom in this Figure.

In exemplary embodiments, the radius R₀ is between 1.04 and 1.55″ (26.4 and 39.4 mm), the radius R₁ is between 1.28 and 1.92″ (32.5 and 48.4 mm), the radius R₂ is between 1.20 and 1.80″ (30.5 and 45.7 mm), the radii R₃ and R₄ are equal to R₁. The radius R₅ is between 1.30 and 1.96″ (33.0 and 49.8 mm), and the radius R₆ is between 1.13 and 1.169″ (28.7 and 29.7 mm).

Further, a length L₁ of skirt 34 as shown in FIG. 8 is between 0.95 and 1.42″ (24.1 and 36.1 mm), whereas a length L₂ of the face 41 is between 0.59 and 0.89″ (15.0 and 22.6 mm).

In exemplary embodiments, a ratio of L₁ to L₂ is preferably between 1.55 and 1.75. A radius of R₀ to R₆ is preferably between 0.85 and 0.95. A ratio of R₁ to R₂ is preferably between 1.05 and 1.15. Another radius of R₀ to R₅ is between 0.075 and 0.85. Further, another radius of R₀ to R₁ is between 0.75 and 0.85.

Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention. 

1. A terminal lead insulator assembly for use in a wound field synchronous machine comprising: a generally cylindrical skirt centered on an axis and extending in an axial direction from a radially larger face, said radially larger face being formed with a plurality of radially outwardly extending ears, said ears including openings for receiving electrical connectors.
 2. The terminal lead insulator assembly as set forth in claim 1, wherein a ratio of a length of said skirt measured along said axis to an axial length of said radially larger face is between 1.55 and 1.75.
 3. The terminal lead insulator assembly as set forth in claim 2, wherein there are six of said ears.
 4. The terminal lead insulator assembly as set forth in claim 3, wherein there are a plurality of radially extending portions extending about said axis, and between adjacent ones of said ears, and a radius being defined to an outer periphery of each of said circumferentially extending sections, with at least one of said radii being less than at least a plurality of others of said radii.
 5. The terminal lead insulator assembly as set forth in claim 4, wherein a ratio of said plurality of other radii compared to said at least one radius is between 1.05 and 1.15.
 6. The terminal lead insulator assembly as set forth in claim 1, wherein a ratio of a radius to an inner periphery of the skirt compared to a radius to the outer periphery of the skirt is between 0.85 and 0.95.
 7. The terminal lead insulator assembly as set forth in claim 1, wherein a ratio of a radius to an inner periphery of the skirt compared to a radius to a center of a cylindrical connection hole extending through said ears is between 0.75 and 0.85.
 8. A rotor assembly for use in a wound field synchronous machine comprising: a main rotor winding; an exciter rotor winding; each of said exciter rotor winding and said main rotor winding rotating with a shaft; a diode pack received radially within a bore in said exciter rotor winding, and there being electrical connections extending between said diode pack to said exciter rotor winding, and electrical connections extending from said main rotor winding to said diode pack; and a terminal lead insulator assembly having a skirt extending towards said main rotor windings from a radially larger face, said radially larger face being formed with a plurality of radially outwardly extending ears, said ears including central openings for receiving said electrical connections.
 9. The rotor assembly as set forth in claim 8, wherein a ratio of a length of said skirt measured along a central axis of said skirt compared to an axial length of said radially larger face is between 1.55 and 1.75.
 10. The rotor assembly as set forth in claim 8, wherein there are a plurality of circumferentially extending portions extending about a central axis of said radially larger face, and between adjacent ones of said ears, and a radius being defined to an outer periphery of each of said circumferentially extending sections, with at least one of said radii being less than at least a plurality of others of said radii.
 11. The rotor assembly as set forth in claim 10, wherein a ratio of said plurality of other radii compared to said at least one radius is between 1.05 and 1.15.
 12. The rotor assembly as set forth in claim 8, wherein a ratio of a radius to an inner periphery of the skirt to a radius to the outer periphery of the skirt is between 0.85 and 0.95.
 13. The rotor assembly as set forth in claim 8, wherein said radially larger face being received radially within said bore.
 14. The rotor assembly as set forth in claim 8, wherein there are six of said ears.
 15. A wound field synchronous machine assembly including: a main stator and an exciter stator; a main rotor winding; an exciter rotor winding; each of said exciter rotor winding and said main rotor winding rotating with a shaft; a diode pack received radially within a bore in said exciter rotor winding, and there being electrical connections extending between said diode pack to said exciter rotor winding, and electrical connections extending from said main rotor winding to said diode pack; and a connection protector having a skirt extending towards said main rotor winding from a radially larger face, said radially larger face being formed with a plurality of radially outwardly extending ears, said ears including central openings for receiving said electrical connections; and said radially larger face being received radially within said bore.
 16. The wound field synchronous machine assembly as set forth in claim 15, wherein a ratio of a length of said skirt measured along a central axis of said skirt compared to a length of said radially larger face is between 1.55 and 1.75.
 17. The wound field synchronous machine assembly as set forth in claim 15, wherein there are six of said ears.
 18. The wound field synchronous machine assembly as set forth in claim 15, wherein there are a plurality of circumferentially extending portions extending about said central axis, and between adjacent ones of said ears, and a radius being defined to an outer periphery of each of said circumferentially extending sections, with at least one of said radii being less than at least a plurality of others of said radii, and a ratio of said at least one radius compared to the plurality of other radii is between 0.80 and 0.95.
 19. The wound field synchronous machine assembly as set forth in claim 15, wherein said radially outer face being received radially within said bore.
 20. A method of assembling a rotor assembly for a wound field synchronous machine comprising the steps of: electrically connecting said main rotor winding to said diode pack by at least a plurality of electrical connections extending through ears in said terminal lead insulator assembly; positioning a diode pack within an exciter rotor, and on a rotor shaft; placing a positioning pin in said diode pack, and placing said positioning pin within an terminal lead insulator assembly, said terminal lead insulator assembly also being positioned on said shaft such that a skirt extends toward a main rotor winding; and electrically connecting said exciter rotor to said diode pack through a plurality of connections each received in other ears in said terminal lead insulator assembly. 